Splice member on stock material units for a dunnage conversion machine

Abstract

Stock material units that may be used in a dunnage conversion machine. For example, stock material units include sheet material that may be fed into the dunnage conversion machine and may be converted thereby into dunnage.

What is claimed is: 
     
       1. A method of assembling a stock material unit for a dunnage conversion machine, comprising:
 providing a three-dimensional body of a continuous, fan folded, first sheet of stock material, the fan folded first sheet having a plurality of substantially parallel folds that define opposing sheet sections including, first and second sheet sections, the first sheet section overlaying the second sheet section, the first sheet being adapted to be drawn from the three-dimensional body and convertible into low-density dunnage by a dunnage converter; 
 non-removably attaching a first portion of a first adhesive to a surface of the first sheet section; and 
 removably attaching a second portion of the first adhesive to the second sheet section, thereby removably securing the first sheet section to the second sheet section, such that the first sheet section can be folded away from the second sheet section to expose the second portion of the first adhesive for contacting and splicing to a second sheet of the stock material, wherein the first adhesive is selected to have sufficient adhesive strength after removal of the second portion of the first adhesive from the second sheet section to splice the first sheet to the second sheet of stock material so that the dunnage converter can draw one of the first or second sheets of stock material into the dunnage converter via the splice by drawing the other of the first or second sheets of stock material into the dunnage converter. 
 
     
     
       2. The method of  claim 1 , wherein the first portion of the first adhesive is non-removably attached to the first sheet section in a position such that the second portion of the first adhesive extends beyond the first sheet section. 
     
     
       3. The method of  claim 1 , wherein:
 providing the three-dimensional body includes the second sheet section that includes a release layer configured such that the second portion of the first adhesive is reusably removable therefrom; and 
 removably attaching of the second portion of the first adhesive to the second sheet section includes removably attaching the first adhesive to the release layer. 
 
     
     
       4. The method of  claim 3 , the first portion and second portions of the first adhesive are attached to the respective surfaces of the first and second sheet sections with the first and second portions of the first adhesive attached to a connector, such that:
 a first portion of the connector is removably attached to the second sheet section via the second portion of the first adhesive; and 
 a second portion of the connector is non-removably attached to the first sheet section via the first portion of the first adhesive. 
 
     
     
       5. The method of  claim 4 , further comprising attaching a base to the second sheet section, wherein the second portion of the first adhesive is removably attached to the second sheet section by removably attaching the second portion of the first adhesive to the base. 
     
     
       6. The method of  claim 4 , wherein the base comprises:
 a first surface that includes the release layer configured such that the second portion of the first adhesive is reusably removable therefrom, wherein removably attaching the second portion of the first adhesive to the second sheet section includes removably attaching the second portion of the first adhesive to the release layer; and 
 an opposite second surface that is attached to the second sheet section via a second adhesive. 
 
     
     
       7. The method of  claim 4 , wherein the three-dimensional body is provided with the connector attached to the first sheet section and spaced from a longitudinal edge of the three-dimensional body, such that when the first sheet section is bent around a fold the second portion of the first adhesive is released from the second sheet section and exposed on the face of the three-dimensional body for contacting and splicing to a second sheet of the stock material placed on the face of the three-dimensional body. 
     
     
       8. The method of  claim 1 , further comprising providing a first crease in the first sheet section to enable the first sheet section to be folded over the first crease for the folding of the first sheet section away from the second section to expose the second portion of the first adhesive. 
     
     
       9. The method of  claim 1 , wherein the first sheet section includes a tapered sheet section that is defined by a slanted fold having a non-parallel orientation relative to an edge of the three-dimensional body, and the first portion of the first adhesive is non-removably attached to the tapered sheet section such that the second portion of the first adhesive extends beyond the tapered sheet section. 
     
     
       10. The method of  claim 9 , wherein the tapered sheet section is generally triangular and includes a peak that is positioned near a longitudinal center of the three-dimensional body. 
     
     
       11. The method of  claim 9 , wherein providing the three-dimensional body includes folding the tapered sheet section at a second fold line that crosses the slanted fold and is oriented parallel to the folds that define the opposing sheet sections, to define the first sheet section overlayed on the second sheet section. 
     
     
       12. The method of  claim 1 , further comprising wrapping a strap about the three-dimensional body to maintain the three-dimensional shape thereof, wherein the strap is spaced from the second portion of the first adhesive leaving the second portion of the first adhesive exposed from the strap for splicing to a second sheet of stock material when the first sheet section is folded from the second sheet section. 
     
     
       13. The method of  claim 12 , wherein the strap that is wrapped about the three-dimensional body includes:
 a load-spreading portion; and 
 a handle portion that is narrower than the load-spreading portion, wherein the strap is sufficiently strong for carrying the three-dimensional body from the handle portion. 
 
     
     
       14. The method of  claim 13 , further comprising positioning the first sheet of stock material against the second sheet of stock material to splice together the first and second sheets of stock material. 
     
     
       15. The method of  claim 14 , wherein positioning the first stock sheet of stock material against the second sheet of stock material further includes removing a strap from the multiple stock material units. 
     
     
       16. The method of  claim 14 , wherein positioning the first stock material unit against the second stock material unit includes positioning the second stock material unit on top of the first stock material unit such that they are spliced together by gravity. 
     
     
       17. The method of assembling a stock material unit of  claim 1 , further comprising:
 folding the first sheet section of the first sheet of stock material away from the second sheet section, thereby exposing the second portion of the first adhesive that is attached to the first sheet section; 
 positioning the second sheet of stock material against the first sheet of stock material, thereby splicing together the first sheet of stock material with the second sheet of stock material; and 
 feeding a first sheet section of the second sheet of stock material into the dunnage conversion machine, such that the second sheet of stock material will pull the first sheet of stock material into the dunnage conversion machine via the second portion of the adhesive to convert the first and second sheets of stock material into dunnage. 
 
     
     
       18. The method of  claim 17 , wherein the continuous sheet of folded material is provided by a fanfolded sheet defined by a plurality of substantially parallel folds that define opposing sheet sections and the release layer is attached to an opposing sheet section. 
     
     
       19. A method of assembling a stock material unit for a dunnage conversion machine, the method comprising:
 providing a continuous sheet of foldable material defining a three-dimensional body, the continuous sheet including a tapered sheet section defined by a slanted fold and positioned adjacent to at least one face of the three-dimensional body; 
 non-removably attaching a first portion of a connector of a splicing assembly to a portion of the tapered sheet section; and 
 removably attaching a release layer to a second portion of the connector. 
 
     
     
       20. A method of splicing multiple stock material units for a dunnage conversion machine, the method comprising:
 folding a first sheet section of a first stock material unit away from a second sheet section, thereby exposing an adhesive side of a splicing connector that is attached to the first sheet section; 
 positioning a second stock material unit against the first stock material unit, thereby splicing together the first stock material unit with the second stock material unit; and 
 feeding a first section of the second stock material unit into the dunnage conversion machine, such that the second stock material will pull the first stock material into the dunnage conversion machine via the splicing connector to convert the multiple stock material units into dunnage.